Mortar and debris collection system

ABSTRACT

Mortar and debris collection systems for cavity wall construction and/or walls constructed from concrete masonry units (CMU), for example, include a mesh body made of a material that is formed with circuitous paths therethrough making the body water-permeable. The mesh body is formed of a material having enhanced hydrophobic properties. The mesh body has a porosity sufficient to permit water to pass therethrough but insufficient to permit mortar and other debris to pass therethrough to weep holes or other water channels covered by the collection debris.

FIELD OF THE INVENTION

This invention generally relates to mortar and debris collection devices, such as are used in association with cavity wall and other types of wall construction. To illustrate, in the course of construction of a masonry cavity wall for example, mortar and other debris falls into the cavity, and may then block weep holes or other water outlets necessary to prevent moisture build-up within the wall cavity. This invention more specifically relates to a device and system for collecting loose mortar and other debris in order to prevent the same from blocking the weep holes that ventilate such a cavity wall. The invention is also applicable to other types of wall construction, such as, for example, walls made of concrete masonry units (CMUs). Moreover, the invention is directed to devices for managing water in various types of wall construction having a mesh body and related structures being formed of materials with enhanced hydrophobic properties.

BACKGROUND OF THE INVENTION

The present invention, in one application, finds its origin, in some embodiments, in so-called masonry cavity wall construction. Masonry cavity walls have inner and outer vertical walls. The inner wall is typically constructed from wood with an inner surface of drywall, structural clay tile, vertical stacks of mortared bricks, or a shear concrete surface. The stacks of bricks that are held together by mortar. A space, or cavity, exists between the two walls, which may be partially filled with insulation. For purposes of this application a “cavity wall” may have a space greater than about 0.4 inches.

A crack in the wall can allow water to enter the cavity. More often, however, moisture can condense on the inside of the wall under changing temperatures. Either way, for various reasons, it is well established that water may collect in the cavity between the inner and outer wall and this is undesirable.

The presence of moisture in the space between the inner wall and outer wall is undesirable for a number of reasons. First, the trapped moisture can degrade the inner and outer wall, causing a weakening of the structure. Second, the presence of water under freezing temperatures may also cause cracks in the walls when the water expands as it freezes. Trapped water in the cavity between the inner and outer walls may cause the walls to become discolored, and may even leak into the dwelling.

To overcome the problems associated with water trapped within a masonry cavity wall, flashing systems and/or other devices are used and weep holes are commonly placed along the base of the outer wall. The flashing systems and weep holes allow water to pass from the cavity to drain outside the wall structure.

During construction of a masonry cavity wall, excess mortar and other debris can and often does fall between the inner and outer wall. When the bricks are stacked during the erection of the outer wall, for example, mortar droppings are squeezed into the space between the walls. The excess mortar, as well as other debris, drops to the base of the cavity, and can block the weep holes.

Wicks have been used in weep holes. For instance a cotton wick, such as a segment of cotton rope, has been used in weep holes. Such wicks can be extended from the weep hole up within the cavity to a height considered sufficient to exceed any build-up of mortar droppings. Moisture within the cavity is absorbed by the wick, and passed to the outside face of the wall. Wicks are typically made from cotton, because nylon or hemp is considered less efficient in transferring water. The cotton wick, however, may become broken or squashed, and will rot with time. Furthermore, wicks, being water absorbent, tend to retain water, which can be undesirable for a number of reasons. Accordingly, the weep hole may still become blocked during and after construction, thereby preventing moisture in the cavity from passing to the outside of the wall and can promote undesirably moist conditions.

Another attempt to overcome the problems associated with obstructed weep holes is described in U.S. Pat. No. 4,852,320. The '320 patent describes embodiments of a mortar collection device located in the wall cavity. One embodiment is adapted to collect mortar but deflect water. This mortar collection device has an upper surface with sufficient inclination to cause moisture to slide off, but is purportedly insufficiently inclined to prevent mortar from falling off. A second embodiment has a plurality of vertically aligned passageways of dimension sufficient to allow moisture to pass therethrough, but of insufficient dimension to allow mortar to pass therethrough. This honeycomb-like mortar collection device of the '320 patent is made from plastic.

It can be seen, nonetheless, that mortar or other debris may still roll down the surface of one or more of the collection devices of the '320 patent and plug a weep hole. Also, the '320 patent mortar collection devices are specially adapted to be carried on reinforcement rods extending between the inner and outer wall. They are not shown adapted to simply rest on the base of the wall, so as to completely cover the weep holes. Furthermore, in the second embodiment of the '320 patent described above having the vertical passageways, small pieces of mortar on other debris may still pass through the holes extending through the unit, thereby allowing the debris to reach the base of the wall and plug the weep holes.

It would be desirable to have a mortar and debris collection device capable of protecting the weep holes, as well as being supportable at different heights on the wall, but allows water to freely pass through. Furthermore, a collection device should preferably prevent mortar droppings and other debris of any appreciable size from reaching the weep holes, but not yield a dam for water passage, in one example by breaking up clumps of mortar. Moreover, the materials of the collection device should ideally not have their function affected negatively by water.

SUMMARY OF THE INVENTION

Accordingly, it is an objective of this invention to provide an improved mortar and debris collection device that can protect one or more weep holes preventing mortar or debris of any significant size from reaching a weep hole and thereby blocking the holes, which is not negatively affected by water.

Another objective is to provide a surface configuration for such a collection device which facilitates adequate dispersal of debris thereon to assure a water path remains to the collection device.

To the foregoing and other ends, the improved mortar and debris collection device of this invention comprises, in one aspect of the invention, a water-permeable body formed with circuitous (non-linear) pathways therethrough, which body can be readily placed within a cavity wall or other wall construction. The inventive collection device can preferably be a non-absorbent water-permeable fibrous or mesh block having a porosity sufficient to permit water to pass therethrough, but insufficient to permit mortar or other debris of appreciable size to pass therethrough. Another embodiment contemplates laterally extending projections formed on a supporting board which form the circuitous path. Another embodiment contemplates that the weep hole is provided with a weep hole body, composed of the same material as the mesh block. A central aspect of the invention herein is that the water-permeable body, and preferably related structures like the weep hole body, is comprised of material provided with enhanced hydrophobic properties compared to prior art devices.

One such collection device is intended to be placed on the wall base within the cavity to cover up and block one or more weep holes openings from the effects of mortar and debris. Water can migrate through the porous mass to a drain outlet, such as the weep holes, but mortar and debris cannot.

It is furthermore contemplated that the collection device may also be placed on existing supports, such as ties, along the walls. No special fixation means for emplacement of the collection device is therefore required, and the collection device need not be specifically adapted for the particular application.

A preferred form of the collection device has upwardly extending protrusions, such as protrusions defining overhangs as well as steps, which serve to break up mortar and debris falling on top of the collection device. This prevents ponding of the material on the surface of the collection device.

In one embodiment of the invention, a plurality of screens having a porosity sufficient to permit water to pass therethrough but insufficient to permit mortar or other larger-size debris to pass therethrough, are organized in an overlapping arrangement in a collection device. The screens are overlapped such that a vertical line perpendicular to the base of the wall must intersect at least one screen in the device. Mortar and the like falling under the influence of gravity within the cavity must thereby contact at least one of the screens, and preferably two, preventing the mortar and debris from reaching the wall base and blocking a weep hole.

There are many and sundry ways to make the water-permeable debris-catching body. However, according to a central feature of the invention, one or all of the inventive collection device, mesh block, porous mesh, screens and related structures, for example, perhaps including weep hole bodies and flashing, pans, trays and so on, are formed of, treated with, or coated by materials having enhanced hydrophobic properties.

BRIEF DESCRIPTION OF THE DRAWINGS

While the drawings depict preferred embodiments of the present invention, they are by way of example only and are not intended to limit the scope of the invention. It is expected that variations and further modifications as well as further applications of the principles of the invention will occur to others skilled in the art and while differing from the foregoing, remain within the spirit and scope of the invention as described.

FIG. 1 is a perspective view partly in section and partially broken away of the invention located in a wall cavity;

FIG. 2 is an enlarged perspective view of a portion of the embodiment of the collection device shown in FIG. 1;

FIG. 3 is a perspective view of another embodiment of the inventive collection device;

FIG. 4 is a perspective view of yet another embodiment of the inventive collection device;

FIG. 5 is a perspective view of still another embodiment of the inventive collection device;

FIG. 6 is a perspective view of a further embodiment of the invention;

FIG. 7 is a perspective view of an embodiment similar to FIG. 2 having a fine porous layer therein;

FIG. 8 is a perspective view of an embodiment having a stepped configuration across its horizontal thickness;

FIG. 9 is a front elevational view of a portion of the fibrous mass.

FIG. 10 is a perspective view, partially in section and partially broken away of an embodiment of a combination flashing and collection device made according to the present invention located in a cavity between an inner and an outer wall;

FIG. 11 is a perspective view of an embodiment of the inventive combination flashing and collection device;

FIG. 12 is a perspective view of another embodiment of the inventive combination flashing and collection device;

FIG. 13 is a perspective view of yet another embodiment of the inventive combination flashing and collection device;

FIG. 14 is a perspective view of a still another embodiment of the inventive combination flashing and collection device.

FIG. 15 is an exterior perspective view of a drainage system in accordance with an embodiment of the invention used in a single wythe masonry wall formed by courses of concrete masonry units (CMUs);

FIG. 16 is a perspective view of a tray of the drainage system of FIG. 15;

FIG. 17 is a sectional view taken along the line 17-17 of FIG. 16;

FIG. 18 is a sectional view taken along the line 18-18 of FIG. 16;

FIG. 19 is a sectional view, similar to FIG. 18, for a tray according to the invention;

FIG. 20 is a perspective view, similar to FIG. 16, illustrating a tray with a peel and stick adhesive layer;

FIG. 21 is an elevation view of a block of water permeable material in a static state used in the drainage system of FIG. 15;

FIG. 22 is a perspective view of the block of FIG. 21 bent to conform to walls of a CMU hollow core;

FIG. 23 is a perspective view, with a CMU removed for clarity, illustrating relationship between the block and the tray in accordance with the invention;

FIG. 24 is a plan view of a tray element in accordance with the invention comprising a plurality of trays;

FIG. 25 is a perspective view of a tray in accordance with the invention to accommodate a rebar;

FIG. 26 is a perspective view of an adapter used with the trays in accordance with the invention to accommodate rebar;

FIG. 27 is an exterior perspective view of a drainage system in accordance with the invention used in a single wythe masonry wall formed by courses of concrete masonry units (CMUs);

FIG. 28 is a plan view of a flashing member with a layer of water permeable material in accordance with the invention;

FIG. 29 is an exterior perspective view of an elongate bar and the flashing material of FIG. 28 mounted to a wall foundation;

FIG. 30 shows a perspective view of a flashing and drainage assembly according to the invention;

FIG. 31 shows a perspective view of a flashing and drainage assembly according to another aspect of the invention;

FIG. 32 shows alternate embodiments of a mesh body;

FIG. 33 shows a perspective view of yet another flashing and drainage assembly;

FIG. 34 shows a partial perspective view of the flashing and drainage device of FIG. 33 with a full end dam;

FIG. 35 shows a partial perspective view of another flashing and drainage device;

FIG. 36 shows a top view of yet another flashing and drainage device according to the invention;

FIG. 37 shows a partial perspective view of the flashing and drainage device of FIG. 36; and

FIG. 38 shows another partial perspective view of the flashing and drainage device according to the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

Brick masonry cavity walls 10, as shown in FIG. 1 include two wythes of masonry separated by an air space. The interior masonry wythe (the inner wall) 12 may be brick, hollow brick, structural clay tile, wood or hollow or solid concrete masonry units, for example. The exterior masonry wythe 14 (the outer wall) is brick. The cavity 16 between the two wythes may be either insulated or left open as air space. The cavity may have, for example, a width from about 0.4 to about 4½ inches.

A common problem associated with a cavity wall construction, as noted above, is how to allow moisture, as from seepage or condensation or other sources, to pass from the cavity to outside the wall. Weep holes 18 creating an unobstructed opening passing from the cavity to the outside of the wall are provided to this end. Generally, the weep holes 18 may be placed approximately two feet apart at the base of the outer wall 14. Moisture collecting in the cavity 16 is intended to run down the cavity wall and be directed by flashing 20 toward the weep holes 18. The flashing 20 can be composed of materials such as sheet metals, bituminous membranes, plastics or vinyls, for example.

A cotton wick 22 may be placed within the weep hole extending into the cavity. The moisture from inside the cavity will be absorbed and passed to the other end of the wick. The end of the wick is left outside the wall to let the moisture evaporate outside the wall. More preferably, the cotton wick 22 is replaced with a plastic mesh weep hole body, having enhanced hydrophobic properties, examples of such materials being discussed in more detail hereinbelow.

In the course of construction of a cavity wall 10 as shown in FIG. 1, mortar 24 and other debris will commonly fall into the cavity 16 between the inner wall 12 and outer wall 14.

FIGS. 1 and 2 show one embodiment of an improved mortar and debris collection device of the present invention. A fibrous or mesh body 28 preferably having enhanced hydrophobic properties according to the present invention rests on the base 26 of the cavity between the inner wall 12 and the outer wall 14, covering at least one weep hole 18. In this embodiment, the body has a generally rectangular shape with a flat bottom edge that will rest flush against the wall 14. The width of the body is roughly determined by the width of the cavity 16.

The body 28 is preferably composed of plastic, such as, for example, the filament-type plastic used to surface walk-off mats. These materials are preferred because they are relatively inexpensive and can be formed into cut-able blocks or sheets. A quantity of one or more of these materials is formed in a mass of random fibers with a density which is sufficient to catch and support mortar and other debris thereon without significant collapse, but allow water to pass freely therethrough. A preferred embodiment of the plastic material is a polyethylene or polyester fibrous mesh such as ENKADRAIN 9120 manufactured by Akzo Industries in Asheville, N.C. or FIBERBOND EM 6645 manufactured by Fiberbond in Michigan City, Ind.

Materials, such as those used in the invention, may be modified to increase their hydrophobicity. For example, polymers may be fluorinated by exposure to mixture of fluorine gas or CF₄ in an inert carrier gas under glow discharge or radio-frequency discharge conditions which generate a fluorine or CF₄ plasma. Suitable carrier gases include helium, argon, and mixtures thereof. See, for example, Handbook of Plastic Films, Abdel-Bary, E. M., ed., pp. 215-217 (Rapra Tech. Ltd., Shawbury, UK, 2003).

In another method, a surface coating of a hydrophobic polymer (e.g., polytetrafluoroethylene) may be deposited as a surface coating under vapor deposition conditions. See, for example, Favia, P., “Plasma Deposition of Fluoropolymer Films in Different Glow Discharge Regimes,” in Plasma Polymer Films, pp. 25-56. (Imperial College Press, London, 2004).

It will be understood that other methods may be used to deposit a surface coating of a hydrophobic polymer onto the base polymer or material of the invention such as spraying, dipping, and so on. See, for example, Chanda, M. and Roy, S. K., Plastic Technology Handbook (CRC Press, Boca Raton, Fla., 2007); in particular, see sections 2.19.1.1-2.19.1.3. In another method, a surface coating of a hydrophobic polymer may be deposited from a polymerizable composition comprising a fluorinated monomer (e.g., perfluoroalkyl acrylates) and suitable crosslinker in the presence of a free-radical initiator (e.g., a chemical initiator, heat, or UV radiation). See, for example, Matyjaszewski, K. and Davis, T. P., Handbook of Radial Polymerization (John Wiley & Sons, 2002).

In another method, the polymer surface may be activated to increase its chemical reactivity by, for example, treatment with an Ar plasma or other ionizing radiation. The activated surface can be subsequently treated with one or more chemicals suitable to increase the hydrophobicity of the polymer surface. For example, the activated surface can be subsequently treated with a substituted silane (e.g., perfluoroalkylsiloxanes or polymethylsilsesquioxane) or a polymerizable monomer which either forms a hydrophobic polymer layer or may be used to attach hydrophobic molecules to the surface. In one example, the activated surface may be treated with glycidyl methacrylate to form a chemically reactive surface and subsequently treated to graft a hydrophobic polymer (e.g., carboxy-terminated polypentafluorostyrene) or other fluorinated molecules (perfluoroalkylamines) onto the polymer surface. See, for example, U.S. Pat. No. 4,954,256. See also, Ikada, Y., Neoh, K. G., Kang, E. T., “Polymer Surfaces, Grafting of in Encyclopedia of Surface and Colloid Science, Somasundaran, P., ed., vol. 6, pages 4936-4957 (2d ed., CRC Press, Boca Raton, Fla. 2006).

In another example, polymers may be formulated, formed, coextruded or laminated with a second polymer having enhanced hydrophobic properties. See, for example, Rauwendaal, C. Polymer Extrusion (4^(th) ed., Carl Hanser Verlag, 2001) In this example, the base polymer of the mesh material may be considered to form a matrix or mixture with the material having enhanced hydrophobic properties.

In another method, hydrophobic filler materials may be introduced into polyethylene or polyesters to generate a blend which has increased hydrophobicity. Suitable fillers include, but are not limited to, fluorinated fused silicas, such as Cab-o-Sil™ fumed silicas or Aerosil™ R972, R7200, and R812. See, for example, Function Fillers for Plastics, Xanthos, M., ed. (2d ed., Wiley-VCH, 2010); in particular, see, Patel, S. H., “Surface Property Modifiers”, Chapter 19, pp 373-406, therein.

It is a central feature of this invention that the porous mesh body, porous wick or weep hole material (mesh weep hole body), is comprised of material preferably having enhanced hydrophobic properties compared to prior art cotton and other materials, such as plastics, used for mortar catching bodies and inserts for weep holes, some examples thereof being detailed herein.

Another feature of the invention provides a mortar and debris collection system, wherein the base portion of the system, comprising one or more flashing member, pan member or tray member, or the like being formed of material(s) having enhanced hydrophobic properties. It will be understood that the method of manufacturing or forming the material is not critical as the invention contemplates any method of making one or more of the structural components of the system of material having enhanced hydrophobic properties, some illustrative examples of which are detailed herein.

Returning to FIG. 1, a mesh weep hole body 22 may be attached to, or formed with, the body 28 to aid in the passage of water from the wall. The mesh weep hole body 22 can serve to hold the body 28 in place. When used with such an integral mesh weep hole body 22, the body 28 would be emplaced when the wick holes were formed. Otherwise, it is contemplated that the mortar collection device of this invention will simply be set at the base 26 of the wall foundation covering respective weep holes 18, without the need of any fixation device. Flashing 20 can furthermore be directly attached to the bottom and/or back of the body 28.

The porosity of the body 28 made from the fibrous material can be quite varied, so long as it effectively serves to strain out the mortar and debris before it reaches the weep holes. Most mortar and debris will be quite large, i.e., greater than ⅛ or 1/16 of an inch or clearly visible to the naked eye, so a porosity sufficient to catch such relatively large particulate matter will suffice to prevent plugging of the weep holes. The body 28 may also function to break up clumps of mortar, which also facilitates penetration and egress of water.

Besides being positionable on the base of the cavity 16, fibrous bodies 28 may be placed on wall tie rods 32 above the base 26 of the cavity. The tie rods 32 are often part of the cavity wall structure, tying the inner wall 12 and the outer wall 14 together.

As particularly shown in FIG. 1, the body 28 may include reinforcing rods 30 extending along the bottom of the body to support and better distribute weight on the body 28 when not simply resting on the base 26 of the cavity 16. The reinforcing rods 30 will better enable a collection device to span adjacent tie rods 32 and still work effectively.

A system using the collection device of FIGS. 1 and 2, for example, would include bodies 28 placed on the base 26 in sufficient number to cover and block some or all of the weep holes 18 in the cavity 16. It could further include bodies 28, having the reinforcing rods 30, placed on tie rods 32.

The body 28 of the device shown in FIG. 2 has trapezoidal-like cutouts 36. Two slanted edges 38 of the body and a bottom edge 40 of the body (the latter running roughly parallel to the longitudinal axis of the body) define the cutout 36. The dove-tailed cutouts 36 thereby formed in the body 28 yield protrusions which help break up the mortar and other debris falling thereon to prevent ponding of moisture in the mortar and debris that collect on the collection device surface. The overhangs formed by the slanted sides 38 are intended to assure that gaps remain in fallen mortar and debris for water to progress to the body 28.

FIG. 3 illustrates another embodiment of this invention having a fibrous mass 41, preferably having enhanced hydrophobic properties, with a stepped configuration along its length created by a series of slanted edges 44. The top step 48 may have a length of approximately 6 to 8 inches, for example. The height of each step may be approximately 4 inches. Again, the stepped cutout 42 is intended to break up mortar and debris falling thereon to thereby prevent the ponding of moisture.

FIG. 4 illustrates another embodiment of this invention with the fibrous mass 50 preferably having enhanced hydrophobic properties and having rectangular cutouts formed by a series of perpendicular edges 54. In a presently contemplated embodiment, the steps would have a height of approximately 4 inches and a length of approximately 8 inches.

FIG. 5 illustrates yet a further embodiment of this invention. The debris collecting fibrous body 58 preferably having enhanced hydrophobic properties has dove-tailed cutouts formed from non-planar curved steps 60. This is another shape for the upper surface of the collection device designed to break up the mortar and other debris falling thereon, to thereby prevent the ponding of moisture on the surface of the body 58.

FIG. 6 illustrates another embodiment of this invention. Three series of planar screens 62, 64 and 66 preferably having enhanced hydrophobic properties and having a porosity sufficient to permit water to pass therethrough but at least collectively insufficient to permit mortar and other debris to pass therethrough are arranged to form the collection device. A first plurality of screens 62 extend on one horizontal plane. On a second and lower horizontal plane, a plurality of screens 64 are arranged in spaced apart relation. On a third and still lower horizontal plane, a plurality of screens 66 are arranged in spaced apart relation, but with portions overlapping with screens 64 of the second horizontal plane. A vertical line extending substantially perpendicular through the collection device of FIG. 6 must therefore pass through at least one and move often two screens in this embodiment.

Generally, the screens should have a width determined by the width of the cavity 16 (FIG. 1). The screens can be formed of a sufficiently rigid screen material to maintain their shape when attached to vertical rods 68 or like supporting structure, or may each be provided with a rigid frame. Screen 62 may have a large mesh size to catch only the larger particles, with screens 64 and 66 having a smaller mesh. Wicks 22 may be attached to the base of the rods 68. Screen 62 might also be omitted entirely, if desired. Whether present or not, however, mortar droppings and other debris falling into the cavity 16 above the screen collection device of FIG. 6 must contact at least one screen to thereby become trapped and isolated from the weep holes.

FIG. 7 illustrates a modified embodiment similar to that of FIG. 2, except that a thin layer of material 70 is provided above the bottom of the fibrous body, which material has the ability to pass water but substantially no visible solids. Such a material could be the type of landscaping material used to control weeds. The layer could be located 1 to 2 inches above the bottom, for example.

FIG. 8 illustrates an embodiment having a stepped upper surface extending across its horizontal thickness, i.e., perpendicular to its long axis. Steps 72 a, 72 b and 73 a, 73 b of the fibrous mass serve to prevent “bridging” of material across the space of the wall cavity (i.e., extending between the inner wall 12 and outer wall 14).

FIG. 9 is a front elevational view of a portion of the fibrous mass. It is a central aspect of the invention that the material of the fibrous mass, whether it is used positioned within or adjacent the weep hole, in place of the wick material, or mortar catching material in the form of bodies or screens as will be detailed herein, attached to the surface of a flashing device, tray or the like, is provided with enhanced hydrophobic properties. A preferred embodiment of the material is a polyethylene or polyester fibrous mesh such as ENKADRAIN 9120 manufactured by Akzo Industries in Asheville, N.C. or FIBERBOND EM 6645 manufactured by Fiberbond in Michigan City, Ind. The material 132 may be of two or more different materials or layers. As seen in FIG. 11, the material 132 is attached to the flashing member in multiple spaced apart longitudinal strips. Preferably, the fibrous mass is further coated, treated or formed of or with materials preferably having enhanced hydrophobic properties as detailed above.

Brick masonry cavity walls 110, as shown in FIG. 10 consists of two wythes of masonry separated by an air space. The interior masonry wythe (the inner wall) 112 may be brick, hollow brick, structural clay tile, wood or hollow or solid concrete masonry units, for example. The exterior masonry wythe 114 (the outer wall) is brick. The cavity 116 between the two wythes may be either insulated or left open as air space. The cavity has a typical width of about 0.4 to 4½ inches, but could be outside this range, although non-standard.

A common problem associated with a cavity wall construction is how to allow moisture, as from seepage or condensation, to pass from the cavity to outside the wall. Weep holes 118 creating a passageway from the cavity to the outside of the wall are provided to this end. Generally, the weep holes 118 will be placed approximately 16 to 24 inches apart at the base of the outer wall 114. Moisture collecting in the cavity is intended to run down the cavity wall and be directed by the combination flashing and mortar and debris collection device 120 of the present invention toward the weep holes 118.

In the course of construction of a cavity wall 110 as shown in FIG. 10, mortar and other debris will commonly fall into the cavity 116 between the inner wall 112 and outer wall 114. The falling mortar is collected on the surface of the combination flashing and mortar and debris collection device 120 of the present invention.

FIGS. 10 and 11 show one embodiment of a combination flashing and debris collection device 120 of the present invention. Device 120 comprises a flashing member 130 having a mortar and debris collection material 132 applied to at least a portion of the surface thereof. Flashing member 130 includes an upper portion 134, an inclined central portion 136 and a lower portion 138. Referring to FIG. 10, the upper portion 134 is preferably received within the inner wall 112 at an elevation above the floor 140 of the cavity 116. The central portion 136 is inclined and extends from the elevated portion of the inner wall 112 through the cavity 116 to a base portion of the outer wall at the floor 140. The lower portion 138 is preferably received at the base of the outer wall 118. The flashing member 130 functions to direct moisture collected in the cavity toward weep holes that are formed at the base of the outer wall 118 in a manner which will be further discussed below. The flashing member may be made from various materials such as sheet metals, bituminous membranes, plastics, vinyls or the like.

A mortar and debris collection material 132 is suitably positioned along at least a portion of the outer surface of the central portion 136 of the flashing member 130. The material 132 functions to permit water to pass therethrough and to substantially prevent mortar and other debris from passing therethrough. The material is preferably a non-absorbent, water-permeable, fibrous mesh material formed with circuitous (non-linear) pathways therethrough. The material preferably having enhanced hydrophobic properties is preferably a mass of random filament-type plastic fibers with a density which is sufficient to catch and support mortar and other debris thereon without significant collapse, but allow water to pass freely therethrough. The overall thickness of the material 132 is preferably between one-eighth inch and one-half inch.

Referring to FIG. 11, in accordance with the invention, the lower portion 138 of the flashing member 130 may be provided with spaced apart strips 142 of the above described mesh materials, which serve to create, reinforce and permit drainage through the weep holes 18 within the mortar joint. The strips 142 may be provided with suitable reinforcement such as solid plastic rods or the like to accommodate the load of the bricks. The outer edge of the lower portion 138 may be provided with an overhang or lip 144. The lip 144 may be a colored strip to make the device invisible on the face of the building.

Referring to FIG. 12, there is shown another embodiment of the invention wherein the same referenced numerals from the embodiment of FIGS. 10 and 11 followed by a prime sign are used to identify common elements. Flashing member 130′ of device 120′ includes an upper portion 134′, an inclined central portion 136′ and a lower portion 138′. Device 120′ includes a plurality of spaced apart structural bars or dowels 145 positioned between the strips 142′ atop flashing member 130′. The bar or dowels 145 serve as further reinforcement to accommodate the load of the bricks.

Device 120′ includes a strip of material 132′ adjacent the intersection of the central portion 136′ and the lower portion 138′. The outer edge of the lower portion 138′ may be provided with an overhang or lip 144′.

Referring to FIG. 13 there is shown yet another embodiment of the invention wherein the same reference numerals from the first embodiment followed by a double prime sign are used to identify common elements. Device 120″ includes a strip of material 132″ adjacent the intersection of the central portion 136″ and the lower portion 138″. A plurality of spaced apart tubes or channels 146 are formed in the upper surface of lower portion 138″ extending about to lip 144″ to create the weep holes within the mortar joint. The tubes or channels 146 alternatively may be integrally formed as a separate member or members positioned immediately adjacent the upper surface of portion 138″. The tubes or channels 146 may be positioned over mesh strips 142 as shown in FIG. 11.

Referring to FIG. 14, there is shown still another embodiment of the invention wherein the same reference numerals from the first embodiment followed by a triple prime sign are used to identify common elements. Device 120′″ may take the form of the embodiments shown in FIGS. 11, 12 and 13 with the addition of a fabric material 150 positioned on top of the mesh material 132′″ to assist in keeping mortar and debris from blocking the passage of water therethrough.

Referring to FIG. 15, a drainage system 220 is illustrated in connection with concrete masonry unit (CMU) wall construction. In the illustrated embodiment of the invention, the drainage system 220 is used in a single wythe masonry wall construction 222 formed by courses 224 of CMUs 226. The wall construction 222 is used on a building structure including a foundation wall 228. In the illustrated embodiment of the invention, the foundation wall 228 comprises a concrete wall. The foundation wall could be of block construction, as will be apparent to those skilled in the art. Referring also to FIG. 23, the drainage system 220 comprises a tray 230 and a pair of blocks 232 of water permeable material.

CMUs 226 most typically have a nominal height of eight inches, a nominal length of sixteen inches and come in nominal widths of eight, ten or twelve inches. Actual sizes are about ⅜ inches less to allow for a ⅜ inch mortar joint. The CMU 226 comprises a hollow concrete block 234 having a web 235 to provide a pair of vertically extending hollow cores or cavities 236 therethrough. The hollow cores or cavities 236 are typically about five inches square. In conventional single wythe masonry wall construction, a first course 224-1 of CMUs 226 is secured to the foundation wall 228 with a layer of mortar. Mortar is also provided between adjacent CMUs 226. A layer of mortar is then placed upon the first course 224-1 and the second course 224-2 is laid on the first course 224-1. Again, mortar is provided between each CMU 226. The CMUs 226 in each course are typically offset from one another as illustrated. As a result, the vertical cores 236 in any course 224 are aligned with the vertical cores 236 in other courses 224 to provide a continuous channel from the top of the wall down to the foundation wall 228, as is well known.

Referring to FIGS. 16-18, the tray 230 comprises a tray unit 238 and a pair of strips 240 (see also FIG. 15) of water permeable material preferably having enhanced hydrophobic properties. The tray unit 238 is of one piece molded plastic construction and has a length and a width less than that of a CMU so that it can be set in mortar and the mortar will set up and secure the tray unit 238 in position. For example, the length of the tray unit 238 may be on the order of twelve inches and the width of the tray unit 238 may be on the order of six inches for an eight inch wide CMU.

The tray unit 238 comprises a peripheral flange 242 formed by a front flange 244, a rear flange 246, a right side flange 248 and an opposite left side flange 250. A web flange 252 is connected transversely, centrally within the perimeter flange 242 and in particular extends from a center of the rear flange 246 to a center of the front flange 244. The perimeter flange 242 and the web flange 252 are U-shaped in cross section, as shown in FIGS. 17 and 18, and open downwardly. A pair of pans 256 and 258 is supported between the perimeter flange 242 and the web flange 252 each on opposite sides of the web flange 252. Particularly, the first pan 256 is supported in an area bound by the left side flange 250, the front flange 244, the web flange 252 and the rear flange 246. Similarly, the right pan 248 is supported in an area bound by the web flange 252, the front flange 244, the right side flange 248, and the rear flange 246. The pans 256 and 258 are generally rectangular in shape and of a size at least as large a shape of the hollow cores 236 (see FIG. 15). The perimeter flange 242 and web flange 252 define an upper surface 260. In the embodiment of FIGS. 16-18, the upper surface 260 is planar and the pans 256 and 258 are likewise planar and parallel to the upper surface 260.

The front flange 244 includes a pair of notches 264 and 266. The notch 264 is associated with the left pan 256 and is centered between the left side flange 250 and the web flange 252. Similarly, the right notch 266 is associated with the right pan 258 and is centered between the web flange 252 and the right side flange 248.

FIG. 19 illustrates a tray unit 238′ in accordance with an alternative embodiment of the invention shown, for example, in FIGS. 17 and 18. This embodiment differs in that the pans, including a left pan 256′, are sloped from the rear flange 246 toward the front flange 244. Indeed, depending on the slope, the rear flange 246 may even be eliminated. The sloped pans enhance drainage toward a front edge 262 of the pan 256′ and thus the front flange 244 to enhance drainage. The pan 256′ could also be sloped from the sides toward the strip 240. In the illustrated embodiments of the invention, the tray unit 238 has a uniform wall thickness on the order of 1/16 inch. Alternatively, the flanges could be solid plastic.

The strips 240 are of a water permeable material having a thickness in the range of about ⅛ inch to ½ inch with ¼ inch being typical. The strips 240 are adhered in any known manner to the pans 256 and 258 and extend transversely beyond the front edge 262 of the pans 256 and 258 and also beyond front flange 244. The strips 240 function to permit water to pass therethrough and to substantially prevent mortar and other debris from passing therethrough. The material is preferably a non-absorbent water-permeable, fibrous mesh material formed with circuitous (non-linear) pathways. The material is preferably a mass of random filament-type plastic fibers. The material is provided with enhanced hydrophobic properties, for example, with a coating of materials having enhanced hydrophobic properties or formed within a matrix including materials having enhanced hydrophobic properties. The strip may also include an outer layer of backing material. The backing material may be a finely woven paper like material which will pass water but not fine debris, such as vermiculite or the like. Overall, the material is sufficient to catch and support mortar and debris without significant collapse, but allow water to pass freely therethrough. The strips 240 may be secured with a suitable adhesive or molded in situ with the tray unit 238.

Referring to FIG. 20, the tray unit 238, similar to that shown in FIG. 16, for example, includes an adhesive layer 268 on the upper surface 260. The adhesive layer 268 is initially covered by a removable film 270 to provide a peel and stick configuration. In the illustrated embodiment of the invention, the adhesive layer 268 covers the entire upper surface 260 and incidentally functions also to protect the pan surfaces, one of which is shown at 258. Alternatively, the adhesive layer could be provided only on the side flanges 248 and 250 and the web flange 252, as necessary or desired (see FIG. 16). Likewise, the adhesive layer could be provided on a bottom surface (not shown), particularly when used with solid flanges. As illustrated, the strips 240 are of a length to extend forwardly of the CMU 226 and then optionally be cut off after the mortar sets or be provided with a score line to be broken off.

Referring to FIG. 21 and FIG. 22, the block 232 comprises a T-shaped body or sheet 272 of water permeable material, having enhanced hydrophobic properties, similar to material of the strips 240. The sheet 272 has a thickness in the range of about ⅛ inch to ½ inch with ¼ inch being typical. The sheet 272 has a top part 274 wider than a CMU core 236 (FIG. 16) and a bottom part 276 narrower than a CMU core 236. For example, with a CMU having a 5×5 inch core, the top part 274 might be about six to eight inches across and about seven inches tall, while the bottom part 276 might be on the order of four inches across and four inches tall. The block 232 is then inserted into a core 236 of the first course 224-1 by bending the bottom part 276 so that it extends horizontally and thus perpendicular to the top part 274 and then curving opposite ends 278 and 280 of the top part 274 to conform to the walls of the core 236. As a result, the curve of the top part 274 gives stability to the mesh material to withstand impact of falling mortar. The proper type of mesh, as described above, will provide a prickly adhesion to the porous walls of the CMUs 226. The horizontal bottom part 276 covers the drainage strip 240 to protect it from being plugged by mortar droppings or granular or foam insulation.

FIG. 23 illustrates a tray unit 230 with one block 232 installed over the left pan 256. For clarity, the CMU 226 (FIG. 15) is not shown in FIG. 23. As is apparent, the block top portion 274 will be supported above or by the tray unit upper surface 260. The bottom portion 276 could be resting directly atop the strip 240 or be supported slightly above the strip 240, as necessary or desired. As shown, the tray 230 is particularly adapted to function with a dual core CMU, such as a CMU 226. The tray unit 238 could be provided with a single pan with two strips 240 as by eliminating the web flange 252 for use with dual cores, or could be provided in half the size with only a single pan for use with a smaller CMU having only a single core.

Referring to FIG. 24 and FIG. 15, a tray element 290 according to an alternative embodiment of the invention is illustrated. The tray unit 290 comprises a plurality of trays 230 formed together of one piece construction to be received beneath a plurality of CMUs 226 in a course. In the illustrated embodiment of the invention, the tray element 290 comprises six trays 230 integrally joined together so that at least one side flange of each tray 230 adjoins a side flange of an adjacent tray. A score line 292 could be provided between adjacent trays 230 for separability in the field if fewer than six trays 230 are required. Also, a score line 292 could be provided between pans 256 and 258 of each tray 230 in the event that an odd number of cores are present. In all other respects, the trays 230 are as described above. As is apparent, the tray element 290 could have more or less than six trays 230. After installation, a block 232, (see FIG. 23) of water permeable material will be positioned above the tray element 290 at each core 236, as described above.

Referring to FIG. 25, a tray 300 is adapted to accommodate rebar in a reinforced wall. The tray unit 300 comprises a pan 302 connected to a left side sloped end wall 304. The end wall 304 includes a semicircular notch 306 to receive a rebar. The notch 306 should be sized larger than the rebar to allow field placement of the tray 300. Front and rear flanges 308 and 310, respectively, extend across the pan 302 and the end wall 304 and are connected by a right side flange 312. A notch 314 in the front flange 314 receives a strip 240 of water permeable material, having enhanced hydrophobic material, as above. As is apparent, the end wall 304 and side flange 312 could be reversed for installation on the opposite side of the rebar.

FIG. 26 illustrates an adapter 320 for use with the tray 230 of FIG. 16 to accommodate rebar. The adapter 320 comprises a plate 322 having a notch 324 on one side edge 326 and a downwardly depending lip 328 on an edge 330 opposite edge 326. The lip 328 can hook over a side flange 248 or 250 of tray 230 so that the notched edge 326 is away form the pan 258 or 256.

Turning back to FIG. 23, though the block 232 is described as a T-shaped sheet element, other configurations for the block 232 could also be used. These blocks include triangular elements, cylindrical elements, as well as other shapes.

Turning to FIG. 27, a drainage system 410 is illustrated in connection with a concrete masonry unit (CMU) wall construction. In the illustrated embodiment of the invention, the drainage system 410 is used in a single wythe masonry wall construction 412 formed by courses 414 of CMUs 416. The wall construction 412 is preferably used on a building structure including a foundation wall 418 with an interior floor 420 inside the foundation wall 418 and exterior grade 422 outside the foundation wall 418. In the illustrated embodiment of the invention, the foundation wall 418 comprises a concrete wall. The foundation wall could be of block r other construction, as will be apparent to those skilled in the art.

Referring to FIGS. 27 and 28, the drainage system 410 includes a flashing member 424, a layer 428 of water permeable material and a plurality of blocks 430 of water permeable material. CMUs 416 are typically about 16″ long wide and come in nominal widths of eight, ten and twelve inches. The CMU 416 comprises a concrete block 432 having a pair of vertically extending cavities 434 therethrough. In conventional single wythe masonry wall construction, a first course 414-1 of CMUs 416 is secured to the foundation wall 418 with a layer of mortar. Mortar is also provided between adjacent CMUs 416. A layer of mortar is then placed upon the first course 414-1 and the second course 414-2 is laid on the first course 414-1. Again, mortar is provided between each CMU 416. The CMUs 416 in each course are typically offset from one another as illustrated in FIG. 27. As a result, the vertical cavities 434 in any one course 414 are aligned with the vertical cavities 434 in other courses to provide a continuous channel from the top of the wall down to the foundation wall, as is well known.

Referring to FIG. 28, the flashing member 424 comprises an elongate body 436 of flashing material. The body may be formed of plastic or sheet metal or the like. In the illustrated embodiment of the invention, the flashing member 424 may comprise a peel and stick material to protect, before and during installation of an adhesive layer provided on an underside of the body 436. The body 436 is defined by an inner or rear edge 438, an outer or front edge 440 and opposite longitudinal ends 442 and 444. Width of the body 436 (front to back) is similar to, or less than, the width of the CMUs. The body 436 has a length sufficient to extend at least across a single cavity 434 or advantageously to extend the entire length of the foundation wall 418.

The layer 428 of water permeable material includes an elongate rectangular longitudinal portion 446 and a plurality of longitudinally spaced shorter, rectangular transverse channel portions 448 extending outwardly therefrom. As used herein, the relative term inner refers to the inner side of the foundation wall, i.e. the rear edge 438 of the flashing member 424, and outer refers to the outer side of the foundation wall, or the front edge 440 of the flashing member 424.

The layer 428 is adhered to a top surface 450 of the flashing member 424, such as by using a suitable adhesive. The longitudinal portion 446 is disposed outwardly adjacent the rear edge 438 at least one inch frontwardly of the rear edge 438. The transverse channel portions 448 extend transversely from the longitudinal portion 446 to the front edge 440 of the flashing member 424. The transverse channel portions 448 are approximately one inch across and are spaced apart in the range of two inches to eight inches, as necessary or desired. The layer 428 has a thickness in the range of about ⅛ inch to ½ inch with ¼ inch being typical. The longitudinal portion 446 serves to interconnect the transverse channel portions 448. In accordance with the invention, the layer 428 could be provided without the longitudinal portion 446 and use only individual transverse channel portions 448 extending to the front edge 440.

In the illustrated embodiment of the invention, the water permeable material used in the layer 428 functions to permit water to pass therethrough and to substantially prevent mortar and other debris from passing therethrough. The material is preferably a non-absorbent water-permeable, fibrous mesh material formed with circuitous (non-linear) pathways. The material is preferably a massive random filament-type plastic fibers with a density which is sufficient to catch and support mortar and other debris thereon without significant collapse, but allow water to pass freely therethrough. A preferred embodiment of the material is a polyethylene or polyester fibrous mesh preferably having enhanced hydrophobic properties. The layer 428 may be provided as one piece or the transverse channel portions 448 may be provided separate from the longitudinal portion 446, as desired. The layer 428 may also be formed of a perforated tubular or cylindrical material. As described herein, the material of the mesh includes an enhanced hydrophobic coating or formed in a matrix of enhanced hydrophobic material(s).

Alternatively, the water permeable material could be made by a partial-fusion process which fuses closed-cell propylene or polyethylene beads together at the tangents of the beads. In this case water would flow between the beads in noncontacting areas. The fused material are formulated of an enhanced hydrophobic material and/or treated and/or coated with materials and/or processes that yield a product having an enhanced hydrophobicity relative to unmodified polyethylene or polyester as in the other examples described herein.

Referring also to FIGS. 29 and 27, the elongate bar 426 consists of ¼ inch high bar stock of plastic placed along the foundation wall 418 near an interior side 452. The flashing member 424, a portion of which is shown, is adhered to the foundation wall 418, preferably with the rear edge 438 raised and overlying the elongate bar 426 to define a dam at the interior side 452 of a single wythe masonry wall. Due to the self adhering nature of the underside of the flashing member 424, the flashing member 424 adheres to the top of the foundation 418 and to the bar 426.

In the illustrated embodiment to the invention, the elevated ridge or elongate bar 426 is used in combination with the flashing member 424 to define a dam, as described. Alternatively, other devices could be used to raise the rear edge to define a dam. Additionally, the foundation wall could be “L” shaped as by having a continuous ridge proximate its rear edge. The flashing member 424 can then be formed or is placed on the foundation to adapt to the foundation shape and thus similarly provide a dam at the interior side of the masonry wall.

Thereafter, and referring back to FIG. 27, the first course 414-1 is constructed in the conventional manner applying mortar between the first course 414-1 and the flashing member 424. As such, the first course 414-1 is constructed on top of the flashing member 424 and layer 428. At least some of the transverse channel portions 448 are generally centered in the cavities 434 and serve to create weep holes within the mortar joint. Enhanced hydrophobic mesh material is used, and furthermore, the transverse channel portions 448 may be provided with suitable reinforcement such as solid plastic rods or the like to accommodate the load of the CMUs 416.

Referring to FIGS. 30 and 31, a drainage system 530 is illustrated for use in connection with cavity wall construction. The drainage system 530 includes three main parts, which will be described in detail below, with a number of additional elements optionally associated therewith and forming various embodiments of the invention. The system 530 includes flashing member 532. The flashing member 532 is provided with one or more weep tabs 534 preferably of enhanced hydrophobic material. The flashing member 532 also includes one or more vertical mesh members 536 preferably of enhanced hydrophobic material.

The flashing member 532 may be any conventional flashing material, for example stainless steel, cold-rolled copper, lead coated copper, galvanized steel, copper laminates and other metals, for example, aluminum, EPDM (man-made rubber), rubberized asphalt, polyvinyl chloride (PVC) and other plastics and composite materials. Preferably, the flashing member 532 is formed of modified bitumen and more preferably, includes a “peel-and-stick” type adhesive and protective backing sheet (not shown) on a backside 538 thereof. The flashing member may be made of enhanced hydrophobic material.

The flashing member 532 shown is rectangular and may advantageously be about 5-7 feet in length and includes a lower flashing portion 540 and a more upright upper flashing portion 542. The flashing member 532 may be other lengths as needed or desired. The lower flashing portion 540 is positioned over the top of a foundation of a building or the like, or a lower course of bricks, or blocks and so on.

The upper flashing portion 542 is positioned generally vertically in a wall cavity as in FIGS. 1 and 10. The weep tabs 534 are positioned atop the lower flashing portion and are sized, shaped and spaced to extend through the weep holes 18 (FIG. 1) of wall 10. The tabs 534 are formed of a porous and/or draining material, like an open mesh plastic, cotton, wool or hemp material capable of functioning to transmit water from atop the flashing 532 and out the weep holes 18 (FIG. 1). In the illustrated embodiment of FIG. 30, the weep tabs 534 are separate strips preferably of enhanced hydrophobic material.

The vertical mesh bodies 536 preferably of enhanced hydrophobic material are positioned on the upper flashing portions 542 and spaced in a manner to deflect and/or prevent debris and mortar from occluding the tabs 534. Furthermore, the depth of the vertical bodies 536 are provided so as to space the vertical flashing portion 542 from the inner face 20 of the outer wall 14 and generally adjacent the inner face of the inner wall 12. In one example, the vertical bodies 536 are about 1 inch thick.

The vertical bodies 536 may be formed of any suitable fibroid water permeable material preferably of enhanced hydrophobic material. The material of the vertical bodies 536 should resist compression when under the weight of debris and mortar and continue to permit water to pass through. In this embodiment, each body 536 has a generally rectangular shape that preferably will rest flush against the wall 14. The width of the body 536 may roughly determined by or correspond to the width of the cavity 16.

The body 536 is preferably composed of non-absorbent plastic, such as, for example, the filament-type plastic used to surface walk-off mats. These materials are preferred because they are water-impervious, relatively inexpensive preferably of enhanced hydrophobic material and can be formed into dividable blocks or sheets. A quantity of one or more of these materials can be formed into a mass of random fibers with a density which is sufficient to catch and support mortar and other debris thereon without significant collapse, but allow water to pass freely therethrough. An objective of the vertical mesh bodies 536 is to separate clumps of mortar and debris and direct the mortar and debris away from the weep tabs 534 and ultimately prevent mortar and debris from preventing the egress of water from within the cavity 16.

The porosity of the body 536 made from the fibrous material can be quite varied, so long as it effectively serves to strain out the mortar and debris before it reaches the weep holes 18. Most mortar and debris will be quite large, i.e., greater than ⅛ or 1/16 of an inch or clearly visible to the naked eye, so an amount of porosity sufficient to catch such relatively large particulate matter will suffice to prevent plugging of the weep holes 18.

The drainage system 530 of this invention may simply be positioned on the wall foundation in cavity 16 without the need of any fixation device. In the alternate, the device 530 may be caulked in place. In yet another embodiment, the flashing backside 538 may be supplied with a pressure sensitive adhesive, which is protected by a backing sheet (not shown). Pressure sensitive adhesives are well known.

The drainage system 530 illustrated includes other features. The lower flashing portion 540 may include a drip edge 544 at a leading edge thereof. The drip edge 544 is preferably stainless steel, although other suitable materials are contemplated by the invention, such as copper, aluminum, plastic, elastomeric materials, and so on. The drip edge 544 may be a strip of material, such as stainless steel bonded or otherwise connected to the bottom of the lower flashing portion 540 or may be an extended lip formed from the flashing portion itself. The lower edge 546 of the drip edge 544 is turned down vertically, preferably about 75 degrees, and may be plain or rolled back to provide a finished edge.

The drainage system 530 may include a base 548, which may function as a pan or the like, underneath the flashing 532, which includes a horizontal base portion 550 and a back leg portion 552. The horizontal base portion 548 is rectangular and is positioned underneath the lower flashing portion 540 and may extend to a position adjacent the drip edge 544. The back leg 552, which preferably is inclined about 30 degrees, forms a dam at the back edge thereof and also causes the flashing member 532 to be inclined at the juncture of the lower and upper portions 540, 542, so as to encourage the egress of water from the flashing and out weep holes 18. The back leg 552 prevents water that infiltrates past the flashing 532 to enter the foundation. As will be shown in more detail below, the back leg 552 may be an angled piece, a separate piece or a triangular piece to produce a dam effect in the base 548 and alternately in the base and flashing 532. In a preferred embodiment, the base 546 and drip edge 544 are formed from a single sheet of material, but also may be separate.

At a top edge 554 of the upper portion 542 of flashing 532 one or more rigid horizontal bars 556 may be optionally provided to enhance the rigidity of the flashing upper portion. The horizontal bars 556 function to prevent the upper portion 542 of the flashing 532 from drooping or being dislodged from against the inner surface 22 of inner wall 12. The bar 556 may be cylindrical or rectangular, for example, and affixed to the upper portion 542 by adhesives or fasteners, like screws. The bar 556 may be provided in a pocket or hem of the flashing material and also may be affixed to the inside surface 22 of the inner wall 12 by screws, anchors, or other fasteners, for example.

A pair of end dams 558 is formed at opposite ends of the lower portion 540 of the flashing 532 to raise the end sections of the flashing. Like the back leg 552, the end dams 558 function to direct water off the flashing and away from the foundation. The end dams 558 may be formed by turning edges of the flashing material 540 upwardly or inserting some thickness of material underneath the flashing. The end dams 558 may also be one or more layer, bead, structure or the like of caulk, glue, water resistant material or the like to form a water resistant or waterproof structure.

An extension 560 of the base 548 is provided for joining together in an end-to-end fashion multiple units 530. The extension 560 is preferably about 4 inches long, but may be anywhere from about 1 inch to 6 inches or more. When adjacent units 530 are joined, the ends of the flashing 532 can be covered with a waterproof tape-like material, like a 4-inch strip of modified bitumen to provide a seal over the joint. The base extension 560 ensures that any water coming through the joint will be directed away from the wall.

The device 530 shown in FIG. 31 is similar to that shown in FIG. 30 except that the weep tabs 534 are all formed and extend from a common body portion 5162A formed of the same material as the weep tabs. The common body portion 5162A is positioned on the flashing 532 on the lower panel 540 thereof so as to align the tabs 534 with vertical mesh towers 536, which themselves are positioned in a spaced configuration on the vertical or upper panel of the flashing. Similarly, the vertical mesh bodies 536 may be joined at lower edges thereof from a common body portion 5162B.

FIG. 32 illustrates several embodiments of the mesh bodies 536. In particular, the mesh bodies may be an inverted wedge shape (inverted trapezoidal) 580, a wedge shape (trapezoidal) 582, wine glass shape 584 and triangular 586, for example.

Referring to FIGS. 33-34, a drainage system 630 is illustrated for use in connection with cavity wall construction. The drainage system 630 includes three main parts, which will be described in detail below, with a number of additional elements optionally associated therewith and forming various embodiments of the invention. The system 630 includes flashing member 632. The flashing member 632 is provided with a single-piece water permeable body 633 preferably of enhanced hydrophobic material and one or more spaced weep tab portions 634 preferably of enhanced hydrophobic material. The water permeable body 633 also includes one or more vertical mesh portions 636 preferably of enhanced hydrophobic material.

The flashing member 632 may be any conventional flashing material, as described above. Preferably, the flashing member 632 includes a “peel-and-stick” type adhesive and protective backing sheet (not shown) on a backside 638 thereof.

Referring also to FIG. 1, the flashing member 632 shown is advantageously be about 5-7 feet in length and includes a lower flashing portion 640 hingeably attached to a more upright upper flashing portion 642. The aspect of the flashing member 632 which functions as a hinge, namely hinge section 643 may be a flexible section of waterproof flashing material, like modified bitumen attached between upper and lower sections 640, 642 of flashing member 632. When folded, the flashing assembly 630 can be packaged in a relatively thin package and unfolded for installation. The flashing member 632 may be other lengths as needed or desired.

The lower flashing portion 640 is positioned over the top of a foundation of a building or the like, or a lower course of bricks, or blocks and so on. The upper flashing portion 642 is positioned generally vertically in a wall cavity 16 and spaced from an inside face of the outer wythe 14 and in contact with an inner face of the inner wythe 12 and keep spaced from the inside face of the outer wythe 14 by pressure between the brick of the outer wythe and the material of the vertical mesh portion 636 preferably of enhanced hydrophobic material.

The water permeable body 633 is preferably formed as a single unitary element including weep tab portions 634 and vertical mesh body portions 636 extending therefrom. The weep tabs 634 are positioned atop the lower flashing portion and are sized, shaped and spaced to extend through the weep holes 18 of a wall 10. The tabs 634 are formed of a porous and/or draining material, preferably like open mesh plastic preferably of enhanced hydrophobic material, or cotton, wool or a hemp material capable of functioning to transmit water from atop the flashing 632 and out the weep holes 18. In the illustrated embodiment, the weep tabs 634 are spaced strips of material extending from body 633 in alignment with the vertical mesh portions 636.

The vertical mesh bodies 636 are positioned on the upper flashing portion 642 and spaced in a manner to deflect and/or prevent debris and mortar from occluding the tabs 634. Furthermore, the depth of the vertical bodies 636 are provided so as to space the vertical flashing portion 642 from the inner face of the outer wall 14 and generally adjacent the inner face of the inner wall 12. In one example, the vertical bodies 636 are about 1 inch thick.

The vertical portions 636 may be formed of any suitable water permeable material as discussed above. The material of the vertical portions 636 should resist compression when under the weight of debris and mortar and continue to permit water to pass through. In this embodiment, each portion 636 has a generally triangular shape that will rest flush against the wall 14. The width of the mesh portion 636 may roughly determined by or correspond to the width of the cavity 16.

The vertical mesh portion 636 may be composed of non-absorbent plastic, such as, for example, the filament-type plastic used to surface walk-off mats. These materials are preferred because they are water-impervious, relatively inexpensive and can be formed into dividable blocks or sheets. A quantity of one or more of these materials can be formed into a mass of random fibers with a density which is sufficient to catch and support mortar and other debris thereon without significant collapse, but allow water to pass freely therethrough. A function of the vertical mesh portion 636 is to separate clumps of mortar and debris and direct the mortar and debris away from the weep tab portions 634 and ultimately keep mortar and debris from preventing the egress of water from within the cavity 16.

The porosity of the mesh portions 636 made from the fibrous material can be any of a wide range of values, so long as it effectively serves to strain out the mortar and debris before the weep holes 18 are occluded. Most mortar and debris will be quite large, i.e., greater than ⅛ or 1/16 of an inch or clearly visible to the naked eye, so an amount of porosity sufficient to catch such relatively large particulate matter should suffice to prevent plugging of the weep holes 18.

The drainage system 630 of this invention may simply be positioned on the wall foundation in cavity 16 without the need of any fixation device. In the alternate, the device 630 may be caulked in place. In yet another embodiment, the flashing backside 638 may be supplied with a pressure sensitive adhesive, which is protected by a backing sheet (not shown). Pressure sensitive adhesives are well known.

The drainage system 630 illustrated includes other features. The lower flashing portion 640 may include a drip edge 644 at a leading edge thereof. The drip edge 644 is preferably stainless steel, although other suitable materials are contemplated by the invention, such as copper, aluminum, plastic, elastomeric materials, and so on. The drip edge 644 may be a strip of material, such as stainless steel bonded or otherwise connected to the bottom of the lower flashing portion 640 or may be an extended lip formed from the flashing portion itself. The lower edge 646 of the drip edge 644 is turned down vertically, preferably about 75 degrees, and may be plain or rolled back to provide a finished edge.

The drainage system 630 may operate alone or may include a base, as discussed above. At a top edge 654 of the upper portion 642 of flashing part 632 one or more rigid horizontal bars 656, also referred to as a termination bar may be optionally provided to enhance the rigidity of the flashing upper portion. The termination bar 656 functions to prevent the upper portion 642 of the flashing 632 from drooping or being dislodged from the desired position against the inner surface of inner wall 12. The termination bar 656 shown in most detail in FIG. 134, may be rectangular, for example, and affixed to the upper portion 642 by adhesives or fasteners, like screws 659. The bar 656 may be provided in a pocket or hem (not shown) of the flashing material and also may be affixed to the inside surface of the inner wall 12 by screws, anchors, or other fasteners, for example. The screws 659 are inserted through screw holes, formed near the upper edge 654 of flashing upper portion 642 to affix the flashing assembly 630 to wall 12. The termination bar 656 may also be provided without screw holes as well.

A pair of end dams 658 (one of which is best seen in FIG. 34) is formed across both the lower portion 640 and upper portion 642 at opposite ends of the flashing 632. The end dams 658 function to direct water off the flashing 632 and away from the foundation. The end dams 658 may be formed by turning edges of the flashing material 640 upwardly, inserting some thickness of material underneath the flashing or building up a berm or raised area on the flashing. When adjacent units 630 are joined, the ends of the flashing 632 are preferably covered with a waterproof tape-like material, like a 4-inch strip of modified bitumen to provide a seal over the joint.

FIG. 35 shows yet another embodiment of a flashing and drainage system 730 according to the invention. The main parts of the flashing and drawings system 730 include the flashing member 732. The flashing member 732 is provided with members 734, 736, which may be separate or combined as detailed above, preferably of enhanced hydrophobic material.

The flashing member 732 is a sheet of material which is structurally capable of being used in a building joint, such as at the bottom or elsewhere of a wall, atop a foundation without destabilizing the wall or joint in which it is used. The flashing member 732 is also made of a material which prevents water from penetrating through the joint. These materials may include conventional materials like metal (steel, copper and aluminum, for example) or elastomeric or membranous materials, modified bitumen and other suitable flashing materials, some of which are detailed above. The flashing member 732 may be of enhanced hydrophobic material.

The flashing member 732 includes a lower flashing portion 740, which is intended to be positioned horizontally or nearly horizontally in the wall. The flashing member includes an upper flashing portion 742 which is angled in a more upright fashion with respect to the lower flashing portion 740.

An optional drip edge 744 is shown depending from a front edge of the lower flashing portion 740. The drip edge 744 may be an angled section of the flashing member 732 or may be a separate sheet of material. Preferably, the drip edge 744 may be a unitary formed segment of the flashing member 732 with a lower edge 746 being lower than the lower flashing portion 740.

The mesh members include weep tabs 734 preferably of enhanced hydrophobic material. The weep tabs 734 are positioned atop the lower flashing portion 740 and are sized, shaped and spaced to correspond and extend through the weep holes 18 (FIG. 1) of wall 10. The tabs 734 are formed of a porous and/or draining material, like an open mesh plastic preferably of enhanced hydrophobic material, or, in the alternate, cotton, wool or hemp material capable of functioning to transmit water from atop the flashing 732 and out the weep holes 18. In the illustrated embodiment, the weep tabs 734 are separate strips preferably of enhanced hydrophobic material. Alternately, the tabs 734 may be joined at rear edge thereof.

The mesh members include vertical mesh bodies 736, which are positioned on the upper flashing portion 742 and spaced in a manner to correspond to the spacing of the weep tabs 734 and deflect and/or prevent debris and mortar from occluding the tabs. Furthermore, the thickness or depth of the vertical bodies 736 may be provided so as to space the vertical flashing portion 742 from the inner face of the outer wall 14 and generally adjacent the inner face of the inner wall 12. In one example, the vertical bodies 736 are about 1 inch thick.

The horizontal and vertical bodies 734, 736 may be formed of any suitable water-permeable material as discussed above and should resist compression to the point of being ineffective when under the weight of debris and mortar and continue to permit water to pass through. In this embodiment, each body 736 has a generally triangular shape that will rest flush against the wall 14. Other shapes are contemplated.

One feature of the illustrated embodiment 730 is that the drip edge 744 extends to a point 745 less than the terminus or end 747 of the flashing lower portion 740. This creates an overlapping portion or tab 749, preferably having a length of about 2 to 4 inches to overlap with an adjacent flashing member and the overlap may include a mesh drainage strip 717 preferably of enhanced hydrophobic material. Preferably, the vertical body 736 adjacent the end 747 is aligned with the end 745 of the drip edge 744. The vertical body 736 also preferably has a termination bar 756 along an upper edge thereof as in an above-detailed embodiment.

FIG. 36 shows yet another embodiment of the flashing and drainage system 830 according to the invention. The generally top-down view shows the system 830 flashing member 832. The flashing member 832 is a flattened sheet-like material sized and shaped to be used, for example, within a cavity wall 10 and more particularly in a building joint, such as over a foundation and under an outer wall built thereon 14 (see FIG. 1). The flashing member 832 includes lower flashing portion 840 and includes a drip edge 844 at a front edge thereof. The drip edge 844 includes a lower drip edge 846 depending therefrom and preferably angled downwardly.

The drip edge 844 stops at a point 845 short of the terminal end 847 of the lower flashing portion 840 a distance D to form an overlap section between point 845 and end 847. The drip edge 844 extends a distance equal to D at an end of the lower flashing portion 840 opposite terminal end 847 to form a overlap tab 841 which when positioned adjacent a second one of device 830 functions to assist in the alignment and fixing in place of adjacent devices 830.

Atop of the lower flashing portion is a mesh body 833 preferably of enhanced hydrophobic material and includes a plurality of weep tabs 834 extending toward the drip edge 844 and spaced to correspond to weep holes formed in outer wall 14 (see FIG. 1). The mesh body 833 extends from terminal end 847 to a point short of the opposite end 853. Between the mesh body 833 and the opposite end 853 of the flashing member 832 is first and second beads of caulk 890C, 890B, a mesh drainage strip 892, and a third bead of caulk 890A on a dam feature 858. The dam feature 858 may be, in the alternate, made by the caulk material, the flashing, flashing material or any suitable material or structure. The opposite end 853 is formed upwardly as part of or on top of the lower flashing member 840 so as to provide the dam feature 858 which causes the flashing to be elevated and sealed at that point.

As in the above examples, the flashing member 832 preferably includes a termination bar 856 to secure the upper portion 842 of the flashing member 832 in place. The flashing upper portion 842 could be extended to provide a through wall flashing feature which is known in the art. The termination bar 856 may be removed or left in place for the through wall feature.

In a preferred embodiment, the total length of a flashing device may be about 7 feet long from end to end, with a usable (non-overlapped) length of about 6 feet. In this embodiment, adjacent flashing units may be overlapped about 6 inches at each end. Of course, other lengths are contemplated by the invention.

FIG. 37 shows a portion of a lower flashing member 940 including a different arrangement of an opposite end 953. The opposite end includes mesh body weep tabs 934 preferably of enhanced hydrophobic material positioned on lower flashing member 940. Next to the weep tab 934 and atop the lower flashing member is an upper gasket forming a first or primary dam 994 including a bead of material 990E on top. Although the drawing shows only one dam 994, there may be multiples thereof. Next to the upper gasket primary dam 994 is a mesh drainage strip 992 preferably of enhanced hydrophobic material. At the extreme opposite end 953 is a raised section of the lower flashing member 940 or a raised amount of material atop the flashing member to form a flashing dam 958. Under the flashing dam 958 and functioning at least as a support therefor may be a second or lower gasket 996. Atop the flashing dam 958 or forming the dam may be a bead of caulk material 990D. Under normal operating conditions, the primary dam 994 will stop all water traveling laterally. If water does pass the primary dam 994, under, for example, sudden water accumulations the emergency drainage strip 992 will exit the water before it flows over the end dam 958. The caulking 990E, 990D also acts as a water tight seal to keep water from reaching a seam between adjacent flashing devices. In the above embodiments, other seals e.g., gaskets or other material, may be substituted for the caulking to provide a seal or dam along the flashing member and/or to adhere adjacent flashing units to each other when installed.

FIG. 38 shows a lower flashing member 1040 similar to that shown in FIG. 37 including a different arrangement of an opposite end 1053. The opposite end 1053 includes mesh body preferably of enhanced hydrophobic material with a plurality of weep tabs 1034 on lower flashing member 1040. Next to the weep tabs 1034 and below the lower flashing member 1040 is a first under gasket 1094 forming a first or primary dam 1058B including a bead of material 1090E on top. Next to the primary dam 1058B is a mesh drainage strip 1092. At the extreme opposite end 1053 is a raised section of the lower flashing member 1040 to form a second or flashing dam 1058A. Under the flashing dam 1058A and functioning at least as a support therefor is a second under gasket 1096. Atop the flashing dam 1058A is a bead of caulk material 1090D. Under normal operating conditions, the primary dam 1058B will stop all water traveling laterally on the flashing member 1040. If water does pass the primary dam 1058B, the emergency drainage strip 1092 will exit the water before it flows over the end dam 1058A. The caulking 1090E, 1090D also acts as a water tight seal to keep water from reaching a seam between adjacent flashing devices. In the above embodiments, other seals e.g., gaskets or other material, may be substituted for the caulking to provide a seal or dam along the flashing member and/or to adhere adjacent flashing units to each other when installed.

While the invention has been described in conjunction with preferred embodiments, it will be obvious to one skilled in the art that other objects and refinements of the present invention may be made with the present invention within the purview and scope of the present invention. 

1. A mortar and debris collection system for a wall having, comprising: a water-permeable body positioned in alignment with at least some channel openings formed through said wall, said body having circuitous non-linear pathways therethrough which interrupt the downward movement of free-falling material and extending from an upper surface upon which water and debris can fall, and yielding a porosity for said body sufficient to permit water to pass therethrough, but mortar and other debris is substantial prevented from passing therethrough, and said water-permeable body having enhanced hydrophobic properties.
 2. The mortar and debris collection device of claim 1, comprising a flashing member.
 3. The mortar and debris collection device of claim 2, wherein the flashing member is formed of a material having enhanced hydrophobic properties.
 4. The mortar and debris collection device of claim 1, comprising a tray member.
 5. The mortar and debris collection device of claim 4, wherein the tray member is formed of a material having enhanced hydrophobic properties.
 6. The mortar and debris collection device of claim 1, comprising a pan member.
 7. The mortar and debris collection device of claim 6, wherein the pan member is formed of a material having enhanced hydrophobic properties.
 8. The mortar and debris collection device of claim 1, further comprising a plurality of weep tabs.
 9. The mortar and debris collection device of claim 8, wherein the weep tabs are formed of a material having enhanced hydrophobic properties.
 10. The mortar and debris collection device of claim 1, further comprising a plurality of weep hole bodies, each of the plurality of weep hole bodies being sized and shaped to be received within a channel opening of the wall.
 11. The mortar and debris collection device of claim 10, wherein the weep hole bodies are formed of a material having enhanced hydrophobic properties. 